Microsoft PowerPoint - Quality Improvement.pptxTopic
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Steps to draw a fish bone diagram
1. List the problems/issues to be studied in the “head of the fish”.
2. Label each “bone” of the “fish”. The major categories typically utilized are:
a. In a manufacturing situation you can use the 6M’s as branch headings(or Bone Headings) to get you started. Machines, Methods, Materials, Measurement, Man and Mother Nature (the environment)
b. In an office environment you can use the 8P’s. Price, Promotion, People, Processes, Place, Policies, Procedures, Product.
Or The 4S’s: Surroundings, Suppliers, Systems, Skills. Surroundings, Suppliers, Systems, Skills.
3. An idea-generating technique (e.g. brainstorming) can be used to identify the factors within each category that may be affecting the problem/issue or effect being studied.
4. Repeat this procedure with each factor under the category to produce sub-factors. Continue asking, “Why is this happening?” and put additional segments each factor and subsequently under each sub-factor.
5. Continue until useful information is received.
6. Analyze the results of the fishbone diagram after team members agree that an adequate amount of detail has been provided under each major category. Do this by looking for those items that appear in more than one category. These become the ‘most likely causes.
7. For those items identified as the “most likely causes“, the team should reach consensus on listing those items in priority order with the first item being the “most probable” cause.
Fishbone Diagram
An Example of When a Cause and Effect Diagram Can Be Used This diagram can be used to detect the problem of incorrect deliveries.
When a production team is about to launch a new product, the factors that will affect the final product must be recognized. factors that will affect the final product must be recognized. The fishbone diagram can depict problems before they have a chance to begin.
Cause and Effect Diagrams Slide 4 of 4
Diagram of the Incorrect Deliveries Example:
Cause & Effect diagram. [Fish Bone chart]
Why Profits are low ?
High MFTG. cost
High MTL. cost
High ADMIN. cost
Delivery of product
Low MKT. share Lack of new product Aging product line Declining MKT. share
Customer perceives poor quality are low ?
Product quality
Lack of existing products High product failure rate
Finding optimal solution by 1. Substituting 2. Combining 3. Modifying 4. Eliminating 5. Replacing
Histograms Histogram Defined
A histogram is a bar graph that shows frequency data.
Histograms provide the easiest way to evaluate the distribution of data.
Histograms
Creating a Histogram Collect data and sort it into categories. Then label the data as the independent set or the dependent set.
The characteristic you grouped the data by would be the independent The characteristic you grouped the data by would be the independent variable.
The frequency of that set would be the dependent variable.
Each mark on either axis should be in equal increments. For each category, find the related frequency and make the horizontal marks to show that frequency.
Histograms
Examples of How Histograms Can Be Used Histograms can be used to determine distribution of sales.
Say for instance a company wanted to measure the revenues of other companies and wanted to compare numbers.
Pareto Charts
Pareto Chart Defined Pareto charts are used to identify and prioritize problems to be solved.
They are actually histograms aided by the 80/20 rule adapted by Joseph Juran.by Joseph Juran. Remember the 80/20 rule states that approximately 80% of the problems
are created by approximately 20% of the causes.
Pareto Charts
Constructing a Pareto Chart First, information must be selected based on types or classifications of defects that occur as a result of a process.
The data must be collected and classified into categories. Then a histogram or frequency chart is constructed showing the number of occurrences.number of occurrences.
Pareto Charts
An Example of How a Pareto Chart Can Be Used Pareto Charts are used when products are suffering from different defects
but the defects are occurring at a different frequency, or only a few account for most of the defects present, or different defects incur different costs. What we see from that is a product line may experience a range of defects. The manufacturer could concentrate on reducing the defects which make up a bigger percentage of all the defects or focus on eliminating the defect that a bigger percentage of all the defects or focus on eliminating the defect that causes monetary loss.
Pareto Charts
Scatter Diagrams
Scatter Diagrams Defined Scatter Diagrams are used to study and identify the possible relationship between the changes observed in two different sets of variables.
Scatter Diagrams
Constructing a Scatter Diagram First, collect two pieces of data and create a summary table of the data.
Draw a diagram labeling the horizontal and vertical axes. It is common that the “cause” variable be labeled on the X axis and the “effect”
variable be labeled on the Y axis.variable be labeled on the Y axis.
Plot the data pairs on the diagram. Interpret the scatter diagram for direction and strength.
Scatter Diagrams
An Example of When a Scatter Diagram Can Be Used A scatter diagram can be used to identify the relationship between the production speed of an operation and the number of defective parts made.
Scatter Diagrams
An Example of When a Scatter Diagram Can Be Used (cont.) Displaying the direction of the relationship will determine whether
increasing the assembly line speed will increase or decrease the number of defective parts made. Also, the strength of the relationship between the assembly line speed and the number of defective parts produced is determined.
Check sheet To check the shape of the probability distribution of a process
To quantify defects by type
To quantify defects by location
To quantify defects by cause (machine, worker)
To keep track of the completion of steps in a multistep To keep track of the completion of steps in a multistep procedure
Check Sheet
Luggage Delay
CONTINUOUS IMPROVEMENT
• Customer needs & competitive costs are moving targets. •To maintain & increase sales revenue companies must
continuously evolve new product features & new process. •To keep costs competitive, companies must continuously reduce
the level of product deficiencies •The Deming’s ( PLAN-DO-CHECK-ACT) cycle provides•The Deming’s ( PLAN-DO-CHECK-ACT) cycle provides the basic process for continuous improvement.
Plan 1
Do 2
Check 3
Act 4
1. Establishing an organization wide quality council 2. Establishing specific quality improvement goals with
time table/ target data. 3. Providing necessary moral & physical support. 4. Scheduling periodic progress reviews & giving recognition
when it is deserved.when it is deserved. 5. Building continuous quality improvement into regular
reward systems 6. Continuously look for ways to reduce waste & improve quality. 7. Adopt survival & generative learning in the organization
ESSENTIAL IMPROVEMENTS ACTIVITIES
changes
design
Standardize the Process
Describe the Process
The changes could result in work being done safely, easily, accurately, faster at lower cost & may provide greater customer satisfaction.
Types of continuous improvement
•Enhancing value to the customer through new & improved product/ service.
• Developing new business opportunities. • Reducing errors, defects & waste. • Improving responsibilities & cycle time performance.• Improving responsibilities & cycle time performance. • Improving productivity & effectiveness in the use of all the recourses
R
THE KAIZEN APPROACH Kaizen- Japanese concept of continuous incremental improvement Kai = Change , Zen= Good , Kaizen means ongoing improvement of all things involving management at all levels at all times.
Kaizen five step plan Step1. STRAIGHTEN UP – separating the necessary, from unnecessary
& getting rid of unnecessary. Step2. PUT THINGS IN ORDER – Put things (tools/materials )
in proper place so that employees always find what they in proper place so that employees always find what they need without waste of time.
Step3. CLEAN UP- Keep work place clean so that work can proceed in an efficient manner.
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KAIZEN STRATEGY
Two external forces act on an organization 1.Improvements made by the competition 2.Ever increasing pressure from customers & market place.
Company fails if employers have “lets stop here, we have done enough , hold performance at this level” attitude. It important to enough , hold performance at this level” attitude. It important to Incorporate Kaizen strategy to maintain & improve working Standard through small gradual improvements. De-link responsibility for maintaining standard to worker with management role in improving standards, produce system approach & problem solving tools for application to realizing the goal.
Not a day to go without some kind of improvement being made in the company unit as a management tool within TQM move.
IMPROVEMENT MADE BY COMPETITIONHOLD PERFORMANCE
AT THIS LEVEL
TIME